Particulate solids for catalyst supports and heat transfer materials

Abstract

A particulate, precalcined low silica content zirconia, especially one stabilized with yttria, is useful as a catalyst support or as a heat transfer solids component for conducting chemical reactions at high temperature, in oxidizing, reducing or hydrothermal conditions, especially in syn gas operations. An admixture of precalcined particulate low silica content zirconia, particularly a low silica content yttria-stabilized zirconia, is employed in a preferred embodiment as a heat transfer solid, in concentrations ranging generally from about 10 wt. % to about 99.9 wt. %, with a particulate catalyst, notably a nickel-on-alumina catalyst, in concentration ranging generally from about 0.1 wt. % to about 90 wt. %. Such an admixture provides a particularly useful catalytic contact mass in high temperature oxidizing, reducing and hydrothermal environments, notably in conducting synthesis gas generation operations. This type of bed promotes continuous, highly efficient heat and mass transfer within the reacting gas phase. The presence of the heat transfer solid as a bed component maintains excellent bed fluidization characteristics, suppressing the normal tendency of the catalyst to sinter or agglomerate; tendencies which promote defluidization of the bed. Moreover, the heat transfer particles of the bed are highly attrition resistant, and are chemically compatible with the catalyst particles of the admixture.

Having described the invention, what is claimed is: 
     
       1. As a composition, a fluidizable contact mass for the production of hydrogen and carbon monoxide from a low molecular weight hydrocarbon contacted with a fluidized bed of said contact mass at elevated temperature in the presence of steam, or oxygen, or both steam and oxygen, which comprises an admixture of   a particulate, fluidizable precalcined zirconia heat transfer solid which contains from 0 percent to about 1 percent silica, based on the weight of the zirconia, in concentration ranging from about 10 percent to about 99.9 percent, based on the total weight of the admixture, wherein the zirconia component of the admixture has a Davison Index measurement of not greater than about 15, and   a catalyst constituted of a refractory inorganic oxide support composited with a metal, or metals, component catalytic for the production of hydrogen and carbon monoxide from low molecular weight hydrocarbons, of fluidizable particle size in concentration ranging from about 0.1 percent to about 90 percent, based on the total weight of the admixture.   
     
     
       2. The composition of claim 1 wherein the average particle diameter of both the zirconia and catalyst components of the admixture ranges from about 30 microns to about 150 microns. 
     
     
       3. The composition of claim 1 wherein the average particle diameter of both the zirconia and catalyst components of the admixture ranges from about 60 microns to about 90 microns, the concentration of the zirconia component of the admixture ranges from about 80 percent to about 99.5 percent, and the catalyst component ranges from about 0.5 to about 20 percent. 
     
     
       4. The composition of claim 1 wherein the zirconia component of the admixture is stabilized with yttria. 
     
     
       5. The composition of claim 4 wherein the yttria is present within the zirconia in concentration ranging from about 1 percent to about 25 percent, based on the weight of the zirconia. 
     
     
       6. The composition of claim 5 wherein the yttria is present within the zirconia in concentration ranging from about 2 percent to about 20 percent. 
     
     
       7. The composition of claim 1 wherein the catalyst component of the admixture is comprised of nickel on alpha-alumina, and the catalyst contains from about percent to about 20 percent nickel, based on the weight of the catalyst. 
     
     
       8. The composition of claim 1 wherein the catalyst component of the admixture is constituted of a zirconia support with which the catalytic metal, or metals, is composited. 
     
     
       9. The composition of claim 8 wherein aluminum, or a lanthanum series metal, or zirconium, or yttrium, or admixture of two or more of these metals, is codeposited with nickel on the particulate zirconia. 
     
     
       10. The composition of claim 1 wherein the average particle diameter of the zirconia component of the admixture ranges from about 60 microns to about 90 microns, contains from 0 percent to about 0.5 percent silica, from about 2 percent to about 20 percent yttria, and the zirconia component of the admixture ranges in concentration from about 80 percent to about 99.5 percent within the admixture; and the catalyst component of the admixture is nickel on alpha-alumina containing from about 5 percent to about 10 percent nickel, and present within the admixture in concentration ranging from about 0.5 percent to about 20 percent. 
     
     
       11. The composition of claim 1 wherein the zirconia component of the admixture has a Davison Index measurement of less than about 10. 
     
     
       12. The composition of claim 1 wherein the zirconia component of the admixture contains from 0 percent to about 0.5 percent silica. 
     
     
       13. The composition of claim 1 wherein the zirconia component of the admixture is precalcined at temperature above about 1400° C.